Hearing protection device

ABSTRACT

A hearing protection device. The hearing protection device includes a band and legs that are rotatable relative to the band. Each leg includes a first leg end and a second leg end. The first leg end is rotatably coupled to the band to allow the leg to rotate relative to the band. The second leg end includes a hole for receiving a stem of a hearing protector. Alternatively, the second leg end includes a socket for receiving a ball formed on a hearing protector shaft. The hearing protection device can accommodate head sizes ranging from the 5th percentile of women to the 95th percentile of men.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates generally to hearing protection devices and inparticular to a hearing protection device including rotatable legs foradjusting the position of hearing protectors.

2. Prior Art

Hearing protectors fall generally into three categories, includingprotectors that cap the entrance to the ear canal; protectors whichenter the ear canal and seal the ear canal prior to the bend in the earcanal (usually referred to simply as semi-insert devices); andprotectors that enter the ear canal and take the bend in the ear canal(sometimes referred to as banded earplugs). Semi-insert hearingprotectors generally protect similarly to earplugs, but usually to alesser level. Semi-insert hearing protectors are also referred to assemi-aural hearing protectors. Semi-insert hearing protectors whichenter the ear canal to a greater degree offer better protection but aresomewhat less comfortable than those which simply cap the ear. Productswhich cap the ear have some of the attributes of both earplugs andearmuffs. Typically, they are used for intermittent noise exposureswhere lighter weight and improved low frequency attenuation aredesirable. As used herein, "hearing protectors" refers generally tohearing protectors falling into one of the three categories describedabove.

FIG. 14 is a front view of a conventional hearing protection devicedisclosed in U.S. Pat. No. 4,461,290. The hearing protection deviceincludes a U-shaped headband 1 having affixed to each of the opposed endportions 3 and 5 an inwardly directed ear obturating pod 2. A pair ofballs 7 and 9 engage a socket formed in the pods 2 and attach the pods 2to the headband 1. While well-suited for its intended purposes, theconventional headband 1 may have certain drawbacks and deficiencies. Forexample, the shape of the headband is such that when the pods 2 aremounted in the wearer's ears, portions of the headband 1 are close to ortouching the wearer's head. This can be irritating and uncomfortable tothe wearer. In addition, there is no mechanism for adjusting theheadband to allow for varying head sizes. A wearer with a large headrequires a large distance between the headband ends 3 and 5.Unfortunately, as the distance between the headband ends 3 and 5increases, so does the tension in the headband 1. Accordingly, wearerswith large heads may experience discomfort due to this high tension inthe headband 1. In order to accommodate varying head sizes, the headband1 must be manufactured in multiple sizes which increases manufacturingcosts. Accordingly, there is a perceived need in the art for a hearingprotection device that can comfortably fit a wide variety of head sizes.

SUMMARY OF THE INVENTION

The above-discussed and other drawbacks and deficiencies of the priorart are overcome or alleviated by the hearing protection device of theinvention. The hearing protection device includes a frame having a bandand a pair of leg supports. A pair of legs are rotatably coupled to theleg supports. Each leg has a first leg end rotatably coupled to arespective leg support and a second leg end for receiving a hearingprotector. Each second end has a mating means (preferably an opening)for receiving a stem portion of the hearing protector. In an alternativeembodiment, the frame of the hearing protection device includes a bandportion and a pair of reverse curve portions integral with the bandportion. The reverse curve portion has an oblique angle formed thereinand reverse curve ends for receiving hearing protectors. An importantfeature of the alternative embodiment that as a result of the reversecurve portions, the hearing protectors at the ends of the band will notcome in contact with a surface after having been placed thereon; therebyleading to improved sanitary conditions since the hearing protectorswill be less likely to be contaminated.

The hearing protector in accordance with this invention provides severalimportant features and advantages relative to the prior art. Forexample, the rotatable legs allow the band to accommodate virtually anyhead size and provide the wearer with both comfort and a variety ofwearing positions.

The above-discussed features and advantages of the present inventionwill be appreciated and understood by those skilled in the art from thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings wherein like elements are numbered alikein the several FIGURES:

FIG. 1 is a front view of a frame of a hearing protection device in afirst embodiment of the invention;

FIG. 2 is a top view of the frame of FIG. 1;

FIG. 3 is a bottom view of the frame of FIG. 1;

FIG. 4 is a side view of the frame of FIG. 1;

FIG. 5 is a view taken along line 5--5 in FIG. 1;

FIG. 6 is a cross-sectional view of one end of a band shown in FIG. 1;

FIG. 7 is a cross-sectional view of a leg shown in FIG. 1;

FIG. 8 is a front view of the frame of FIG. 1 fitted with a first typehearing protector;

FIG. 9 is a front view of the frame of FIG. 1 fitted with a second typeof hearing protector;

FIG. 10 is a front view of the frame of FIG. 1 fitted with a third typeof hearing protector;

FIGS. 11A-11B are a cross-sectional views of a hearing protectors foruse with the hearing protection device of FIG. 1;

FIG. 12 is a front view of a frame of a hearing protection device in asecond embodiment of the invention;

FIG. 13A is a view taken along line 13A--13A of FIG. 12;

FIGS. 13B-13C are side views of the frame of FIG. 12 placed on asurface;

FIG. 14 is a front view of a conventional hearing protection device;

FIGS. 15A-C are perspective views depicting the hearing protectivedevice of this invention in three different positions on a wearer'shead;

FIGS. 16A-16C are front views of the frame fitted with a variety ofhearing protectors;

FIG. 17 is a cross-sectional view of a frequency attenuating hearingprotector for use with the present invention;

FIG. 18 is an exploded view of an alternative system for mounting ahearing protector to the frame; and

FIG. 19 is a partial cross-sectional view of a hearing protector mountedto the frame using the system of FIG. 18.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a front view of the frame of the hearing protection device ina first embodiment of the invention. The frame is shown generally at 10.The frame 10 includes a band 12 and a pair of legs shown generally at14. The band 12 is generally U-shaped and is made from a resilient,flexible material such as plastic. The band 12 has two leg supports 16,each of which forms one half of a swivel or rotating joint between theband 12 and the leg 14. The leg support 16 is integral with the band 12and in an exemplary embodiment is a spherical segment. The leg 14includes a first leg end 18 which is integral with leg 14 and, in anexemplary embodiment, is a spherical segment. The flat faces of thefirst leg end 18 and the leg support 16 are placed opposite each otherto form a swivel joint. The details of the swivel joint are describedbelow with reference to FIGS. 6 and 7. The swivel joint allows the firstleg end 18 to rotate relative to the leg support 16 thereby allowing theleg 14 to rotate relative to the band 12. The band 12 lies substantiallyin a plane and as the legs 14 are rotated, a plurality of angles aredefined between the leg 14 and the plane. It is understood that the band12 and leg supports 16 need not lie in the same plane as shown in FIG.4. Indeed, as shown in FIGS. 15 A, B and C (and discussed hereafter) theleg supports 16 may lie in a plane different than the band 12 and eachleg 14 will rotate through a plurality of angles between the leg 14 andthe plane of the leg supports 16. The leg 14 includes a second leg end20 for receiving a hearing protector 100 (shown in FIGS. 11A and 11B).In an exemplary embodiment, the second leg end 20 is a sphericalsegment. It will be appreciated that second leg end 20 may comprise anyother desired functional shape such as ovular, triangular, etc. Theouter dimension of the second leg end 20 is preferably equal to theaverage concha bowl opening so that the second leg end 20 cannot beinserted into the ear canal but is preferably insertable (and rests in)the concha bowl (so that the earplug attached to end 20 is permitted tofreely articulate in the ear canal). FIGS. 2-5 are various views of theframe of the hearing protection device of FIG. 1 and areself-explanatory.

FIG. 6 is a cross-sectional view of the leg support 16 and FIG. 7 is across-sectional view of the leg 14. The leg 14 includes first leg end18, second leg end 20 and leg body 22. The first leg end 18 has a planarsurface 28 and a post 24 substantially perpendicular to the planarsurface 28. The post 24 has a neck region 26 where the diameter of thepost 24 is smaller than the diameter of the end of the post 24 away fromthe planar surface 28. The leg support 16 includes a hole 32 formedtherethrough for receiving the post 24. The neck 26 snap-lockedlyengages a ridge 30 formed in the hole 32. The ridge 30 has an innerdiameter that is smaller than the inner diameter of the hole 32. Thatis, the ridge 30 extends away from the inner wall of the hole 32. Theinterference fit between the neck 26 and the ridge 30 holds the leg 14to the band 12 while allowing the post 24 to rotate within the hole 32.Because the band 12 and the leg 14 are made from a resilient material,such as plastic, the interference fit between the neck 26 and the ridge30 can be defeated by pulling the post 24 out of the hole 32 ifnecessary.

The planar surface 28 of the first leg end 18 is at an oblique anglerelative to the major axis of the leg body 22. This causes the leg 14 tobe angled towards the interior of the U-shaped band 12 as shown inFIG. 1. This results in the second leg ends 20, which hold the hearingprotectors as shown in FIGS. 8-10, being close to the wearer's head andthe band 12 being away from the wearer's head. Because the band 12 ispositioned away from the wearer's head, it is less likely that the band12 will contact and irritate the wearer. Thus, the comfort of thehearing protection device is improved over the prior art.

The frame 10 allows legs 14 to be rotated to comfortably accommodatehead sizes ranging from, for example, the 5th percentile of women to the95th percentile of men. The legs 14 may be rotated while the hearingprotection device is being worn to allow modification of the fit withoutremoving the hearing protection device. In addition, the hearingprotection device can be worn with the band 12 under the chin (as shownin FIG. 15A), over the top of the head (as shown in FIG. 15B), or behindthe back of the head based on the wearer's preference (as shown in FIG.15C).

The second leg end 20 includes a hole 34 formed therein for receivingvarious hearing protectors 101-103 as shown in FIGS. 8-10. As mentionedabove, the hearing protectors may be protectors that cap the entrance tothe ear canal; protectors which enter the ear canal and seal the earcanal prior to the bend in the ear canal; or protectors that enter theear canal and take the bend in the ear canal. FIGS. 16A-16C illustrateadditional hearing protectors 110-112 that may be mounted to the secondleg end 20. FIG. 17 is a cross-sectional view of a hearing protector 113that may be mounted to the second leg end 20. The hearing protector 113attenuates sound over a wide frequency range uniformly. Additionaldetails of the hearing protector in FIG. 17 are provided in U.S. Pat.No. 5,113,967, the fill contents of which are incorporated herein byreference. The hearing protection device of the present inventionprovides a comfortable fit regardless of the size or shape of thehearing protectors mounted in the second leg ends 20.

As shown in FIGS. 11A and 11B, a hearing protector 100 comprises a foamportion 106 coupled to a stem 104. The hearing protector in FIG. 11A isa conventional hearing protector in which the foam portion 106 is gluedto the stem 104. The hearing protector shown in FIG. 11B is an improveddesign in which the stem 104 is made from a porous material and the foam106 interpenetrates the pores in the stem 104 to form a mechanical bond.This hearing protector shown in FIG. 11B is described in additionaldetail below.

In an exemplary embodiment, the foam portion 106 is a dynamically stifffoam. A suitable dynamically stiff foam is described in commonlyassigned U.S. Pat. No. 5,420,381, the contents of which are incorporatedherein by reference. Alternatively, the foam portion 106 may compriseany other conventional earplug foam material such as the foam disclosedin U.S. Reissue Pat. No. 29,487, all of the contents of which are alsoincorporated herein by reference. The stem 104 is placed in the hole 34.The use of hole 34 and stem mounted hearing protector 100 allows thewearer to change hearing protectors easily. Hole 34 includes a curvedarea 36 (shown in FIG. 7) that eases placement of the hearing protector100 in hole 34. The stem 104 is preferably flexible so that it flexes asthe wearer adjusts the hearing protective device. A non-pliable stem maycause discomfort as the wearer adjusts the hearing protection device. Byusing a flexible stem 104, an extra degree of freedom is introduced intothe hearing protection device. The foam portion 106 moves along with thewearer's head and provides additional comfort.

To provide a tight fit in the hole 34, the stem 104 should be made froma compressible, resilient material and have a diameter slightly largerthan the diameter of hole 34. When the stem 104 is positioned in hole34, the stem 104 will press against the wall of hole 34 and provide afriction fit. The hole 34 need not be formed completely through thesecond leg end 20 for the stem 104 to be securely mounted to the secondleg end 20. However, if the hole 34 is formed all the way through thesecond leg end 20, the stem 104 can be pushed out of the second leg end20 to aid removal of the hearing protector 100 if necessary.

As previously mentioned with reference to FIG. 11B, in an exemplaryembodiment, the stem 104 is made from a porous material, such as thatdisclosed in the U.S. Patent Application filed contemporaneouslyherewith entitled "Hearing Protective Device Comprising a Foam and aPorous Component, and Method of Manufacturing Thereof" which isincorporated herein by reference. The porous material is both flexibleand compressible. The porous material is preferably a polymer orcombination of polymers in the form of small particles of one or moresize ranges bonded in such a way as to leave voids or pores within thematerial. The pores may be of varying sizes. Preferably, the pore volumeis in the range from about ten percent to about ninety percent of thetotal volume, with the most preferred pore volume being in the rangefrom about thirty to about sixty percent of the total volume. Aparticularly preferred porous component is Swab-002 made from INTERFLO®,available from Interflo Technologies, Brooklyn, N.Y. The foam 106interpenetrates the pores in the porous stem 104 to mechanically bondthe foam portion 106 to the stem 104.

It will be appreciated that an ear protective device may be mounted tothe ends of legs 14 in any suitable manner in addition to the hole 34with mating stem 104 approach shown in the preferred embodiments. Forexample, a foam or other earplug device could be attached using a balland socket configuration as in prior art FIG. 14, or any other approachmay be used whereby the earplug is attached to leg 14.

FIG. 12 is a front view of an alternative frame for a hearing protectiondevice. The frame is shown generally at 50 and includes a band portion52 and reverse curve portions 54. The reverse curve portions areintegral with the band portion 52. The center of gravity 56 is locatedwithin the band portion 52. The reverse curve portions 52 each includesa reverse curve end 20' which is similar to the leg second ends 20described above with reference to FIGS. 1-7. The reverse curve portion54 includes an oblique angle p60 . The angle α directs the reverse curveends 20' of the reverse curve portions 54 towards the wearer's head.This provides additional space between the band 52 and the wearer's headwhich reduces the likelihood that the band 52 will contact or irritatethe wearer.

FIG. 13A is a view of the frame 50 taken along line 13A--13A of FIG. 12.The reverse curve ends 20' of the reverse curve portions 54 receive thestem 104 of the hearing protector 100 as shown in FIG. 11B. The use of ahearing protector 100 having a flexible stem 104 is also advantageous tothe fit of the hearing protection device shown in FIG. 12. As describedabove, this allows the foam portion 106 of the hearing protector 100 tomove relative to the reverse curve end 20', and provides a morecomfortable fit.

The reverse curve portions 54, along with the location of the center ofgravity 56 within the band 52, reduce the likelihood that the hearingprotectors mounted in reverse curve ends 20' will become contaminatedwhen the frame 50 is placed on a surface. As shown in FIGS. 13B and 13C,when the frame 50 is placed on a surface in either orientation, thereverse curve ends 20' are positioned above the surface. This reducesthe likelihood that the hearing protectors mounted in the reverse curveends 20' will become contaminated and thereby leads to improved sanitaryconditions.

FIG. 18 is an exploded view of an alternative system for mounting ahearing protector to the frame. A shaft 210 includes a first ball 212and a second ball 216 joined by a shaft neck 218. The first ball 212engages a socket 202 (shown in FIG. 19) formed in the frame end 200. Thesocket 202 may be formed in either the second leg end 20 shown in FIG. 1or the reverse curve end 20' shown in FIG. 12. The second ball 216engages a hearing protector 220. The hearing protector 220 shown in FIG.18 is a multiple flange earplug similar to the earplug described in U.S.Pat. No. 4,867,149, the full contents of which are incorporated hereinby reference. It is understood, however, that any hearing protector maybe configured for use with shaft 210.

FIG. 19 is a partial cross sectional view of the hearing protector 220mounted to the frame end 200 through shaft 210. The first ball 212 isplaced within socket 202. The socket 202 includes a lip 204 that extendsinto the socket 202 to reduce the diameter of the opening of the socket202. The outer diameter of the first ball 212 is slightly smaller thanthe inner diameter of the socket 202. The frame end 200 is made from aresilient material (e.g., plastic) and the lip 204 flexes to allow thefirst ball 212 to be placed within the socket 202. The lip 204 thenreturns to its original position once the first ball 212 is placed inthe socket 202. The interference fit between the lip 204 and the firstball 212 retains the shaft 210 in the frame end 200. As previouslymentioned, either the second leg end 20 or the reverse curve end 20' mayinclude the socket 202 and lip 204. The hearing protector 220 is thenplaced on the shaft 210 and retained on the shaft by the interferencefit between the second ball 216 and the hearing protector 220.

The mounting system of FIGS. 18 and 19 allows the hearing protector 220to rotate away from a center line of the socket 202 by an angle α. FIG.19 illustrates the hearing protector 220 in three different positions.In an exemplary embodiment, α equals 27°. The use of the ball and socketmounting system shown in FIGS. 18 and 19 introduces additional degreesof freedom in the hearing protection device. This allows the wearer tofinely adjust the position of the hearing protectors for a morecomfortable fit.

The present invention provides a hearing protection device thatcomfortably fits head sizes ranging from the 5th percentile of women tothe 95th percentile of men. This is accomplished through legs having afirst end rotatably coupled to a band and a second end for receivinghearing protectors. To increase comfort, the hearing protector may bemounted on a flexible stem which allows the hearing protector to moverelative to the leg. Alternatively, a ball and socket mounting systemmay be used to allow the wearer to finely adjust the position of thehearing protectors relative to the frame.

While preferred embodiments have been shown and described, variousmodifications and substitutions may be made thereto without departingfrom the spirit and scope of the invention. Accordingly, it is to beunderstood that the present invention has been described by way ofillustration and not limitation.

What is claimed is:
 1. A frame for a hearing protection device, said frame comprising:a band having a pair of ends; and a pair of legs, each of said legs having a first end rotatably coupled to one of said band ends and a second end for receiving a hearing protector, said legs being rotatable with respect to said band while said hearing protection device is worn; wherein said band ends each includes a first hole formed therein and each of said first ends includes a post for engaging said first hole to rotatably couple said first end to said band end; and wherein said post comprises a neck having a diameter less than the diameter at a tip of said post, and said first hole includes a ridge having a diameter smaller than the diameter of said first hole, wherein said ridge engages said neck when said post is placed within said first hole.
 2. A frame for a hearing protection device, said frame comprising:a band having a pair of ends; and a pair of legs, each of said legs having a first end rotatable coupled to one of said band ends and a second end for receiving a hearing protector, said legs being rotatable with respect to said band while said hearing protection device is worn; wherein each of said legs further comprises a leg body connecting said first end and said second end, said first end further comprising a planar surface at an oblique angle relative to said leg body.
 3. The frame of claim 2 wherein each of said band ends comprises a first hole formed therein and each of said first ends includes a post for engaging said first hole, said post extending away from and perpendicular to said planar surface.
 4. The frame of claim 3 wherein said post comprises a neck having a diameter less than the diameter at a tip of said post, and said first hole comprises a ridge having a diameter smaller than the diameter of said first hole, wherein said ridge engages said neck when said post is placed within said first hole.
 5. The frame of claim 2 wherein each said second end has a hole formed therein.
 6. The frame of claim 2 wherein each said second end has a socket formed therein.
 7. A hearing protection device comprising:a band having a pair of ends; and a pair of legs, each of said legs having a first end rotatable coupled to one of said band ends and a second end for receiving a hearing protector, said legs being rotatable with respect to said band while said hearing protection device is worn; wherein the hearing protector includes a stem and said second end has a second hole formed therein for receiving the stem.
 8. The frame of claim 7 wherein said second hole is formed completely through said second end.
 9. A hearing protection device comprising:a band having a pair of ends; a pair of legs, each of said legs having a first end rotatably coupled to one of said band ends and a second end for receiving a hearing protector, said legs being rotatable with respect to said band while said hearing protection device is worn; and a hearing protector coupled to the second end of each leg wherein said hearing protector includes a stem and each of said second ends includes a hole for receiving said stem.
 10. A hearing protection device comprising:a frame having a pair of distal ends, each of said ends having an opening formed therein; and a hearing protector mounted to each of said ends, said hearing protector including a stem for insertion in said opening.
 11. The hearing protection device of claim 10, wherein said hearing protector is an ear cap.
 12. The hearing protection device of claim 10, wherein said hearing protector is a semi-insert device.
 13. The hearing protection device of claim 10, wherein said hearing protector is an ear plug.
 14. The hearing protection device of claim 10, wherein said hearing protector includes a foam portion connected to said stem.
 15. The hearing protection device of claim 14, wherein said stem is made from a porous material.
 16. The hearing protection device of claim 15, wherein said stem includes pores and said foam portion interpenetrates said pores to mechanically bond the foam portion to said stem.
 17. The hearing protection device of claim 10 wherein each of said ends has an outer dimension substantially equal to an average concha bowl opening.
 18. The hearing protection device of claim 10 wherein said opening is formed completely through said end. 